Rosemount BINOS 100 Series Analyzers including OXYNOS 100, HYDROS 100 and CAT 100-2nd Ed. Owner's manual

Instruction Manual

HAS1xE-IM-HS

January 2006

www.EmersonProcess.com

BINOS

®

100 Series Gas Analyzers

BINOS

®

100, BINOS

®

100 M

BINOS

®

100 2M, BINOS

®

100 F

OXYNOS

®

100, HYDROS

®

100, CAT 100

Emerson Process Management

Manufacturing GmbH & Co. OHG

Industriestrasse 1

D-63594 Hasselroth

Germany

T +49 (0) 6055 884-0

F +49 (0) 6055 884-209

Internet: www.EmersonProcess.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management designs, manufactures and tests its products to meet

many national and international standards. Because these instruments are sophisticated

technical products, you MUST properly install, use, and maintain them to ensure

they continue to operate within their normal specifications. The following instructions

MUST be adhered to and integrated into your safety program when installing, using and

maintaining Emerson Process Management products. Failure to follow the proper

instructions may cause any one of the following situations to occur: Loss of life; personal

injury; property damage; damage to this instrument; and warranty invalidation.

·

Read all instructions prior to installing, operating, and servicing the product.

· If you do not understand any of the instructions, contact your Emerson Process

Management representative for clarification.

· Follow all warnings, cautions, and instructions marked on and supplied with the

product.

· Inform and educate your personnel in the proper installation, operation, and

maintenance of the product.

· Install your equipment as specified in the Installation Instructions of the

appropriate Instruction Manual and per applicable local and national codes.

Connect all products to the proper electrical and pressure sources.

· To ensure proper performance, use qualified personnel to install, operate, update,

program, and maintain the product.

· When replacement parts are required, ensure that qualified people use replacement

parts specified by Emerson Process Management. Unauthorized parts and procedures

can affect the product’s performance, place the safe operation of your process at risk,

and VOID YOUR WARRANTY. Look-alike substitutions may result in fire, electrical

hazards, or improper operation.

· Ensure that all equipment doors are closed and protective covers are in place,

except when maintenance is being performed by qualified persons, to prevent

electrical shock and personal injury.

The information contained in this document is subject to change without notice.

1

st

edition 3/2005

2

nd

edition 1/2006

Emerson Process Management Manufacturing GmbH & Co. OHG S-I

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

PREAMBLE

This instruction manual provides information about BINOS

®

100 series gas

analyzers concerning subassemblies, functions, procedures, installation,

operation and maintenance.

This instruction manual covers several BINOS

®

100 series analyzer variations

and therefore may describe configurations and/or options not part of your

specific analyzer.

Installation and operation of instruments intended to be installed and operated

in HAZARDOUS AREAS is NOT COVERED by this instruction manual, but part

of the specific instruction manual shipped together with such analyzers

because of the special requirements for working in hazardous environments!

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout

this publication.

Highlights an operation or

maintenance procedure,

practice, condition, state-

ment, etc.

If not strictly observed, could

result in injury, death, or long-

term health hazards of

personnel.

Highlights an operation or

maintenance procedure,

practice, condition, state-

ment, etc.

If not strictly observed, could

result in damage to or

destruction of equipment, or

loss of effectiveness.

NOTE

Highlights an essential operating

procedure, condition or statement.

Emerson Process Management Manufacturing GmbH & Co. OHGS-II

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

All graphical symbols used in this product are from one or more of the following standards:

EN61010-1, IEC417, and ISO3864.

Explosion Hazard!

Harmful (to Health)!

Elektrostatic discharge (ESD)

Toxic!

Heavy Instrument!

Disconnect from Mains!

IMPORTANT

SAFETY INSTRUCTIONS

WIRING AND INSTALLATION OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should be

strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states

should also comply with the following unless superseded by local or National Standards.

1. Adequate earth connections should be made to all earthing points, internal and external,

where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

3. To ensure safe operation of this equipment, connection to the mains supply should only be

made through a circuit breaker which will disconnect

all circuits carrying conductors during

a fault situation. The circuit breaker may also include a mechanically operated isolating

switch. Circuit breakers or switches must comply with a recognized standard such as

IEC947. All wiring must conform with any local standards.

4. Where equipment or covers are marked with the symbol to the right,

hazardous voltages are likely to be present beneath. These covers should

only be removed when power is removed from the equipment — and then

by trained service personnel only.

5. Where equipment or covers are marked with the symbol to the right, there

is a danger from hot surfaces beneath. These covers should only be removed

by trained service personnel when power is removed from the equipment.

Certain surfaces may remain hot to the touch.

6. Where equipment or covers are marked with the symbol to the right, refer

to the Instruction Manual for instructions.

7. Further graphical symbols used in this product:

Emerson Process Management Manufacturing GmbH & Co. OHG S-III

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

This instrument has left the factory in

compliance with all applicable safety

regulations.

To maintain this operating condition, the user

must strictly follow the instructions and consider

the warnings in this manual or provided on the

instrument.

Before switching on the instrument, verify that

the electrical supply voltage matches the

instrument´s operating voltage as set in the

factory.

Any interruption in the instrument´s ground line,

whether inside or outside the instrument, or

removal or interruption of its ground line

connection, could result in hazardous operating

conditions. Intentionally interrupting the

instrument´s protective ground is strictly prohi-

bited.

Opening cover panels could expose voltage-

carrying components. Connectors may also be

under voltage. The instrument must be

disconnected from all electrical supplies before

attempting any calibrations, maintenance

operations, repairs or component

replacements requiring opening of the

instrument. Any calibrations, maintenance

operations, or repairs that need the instrument

to be opened while connected to electrical

supplies should be subject to qualified

technicians familiar with the hazards involved

only!

Use only fuses of the correct type and current

ratings as replacements. Using repaired fuses

and short circuiting of fuse holders is prohibited.

Observe all applicable regulations when

operating the instrument from an auto-

transformer or variac.

Substances hazardous to health may emerge

from the instrument‘s exhaust.

Please pay attention to the safety of your

operation personnel. Protective measures

must be taken, if required.

OPERATING AND MAINTAINING THIS APPARATUS

SAFETY INSTRUCTIONS

Emerson Process Management Manufacturing GmbH & Co. OHGS-IV

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

SAFETY INSTRUCTIONS

TOXIC GASES !

This unit’s exhaust may contain toxic gases such as sulfur dioxide.

These gases can cause serious injuries.

Aviod inhalation of the exhaust gases at the exhaust fitting.

Connect exhaust outlet to a safe vent. Check vent line and connections for leakage.

Keep all fittings tight to avoid leaks. See section 9-2, page 9-3 for leak test information.

ELECTRICAL SHOCK HAZARD !

Do not operate without covers secure. Do not open while energized. Installation requires

access to live parts which can cause death or serious injury.

For safety and proper performace this instrument must be connected to a properly

grounded three-wire source of power.

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective systems

may be impaired.

AUTHORIZED PERSONNEL

To avoid loss of life, personal injury and damage to this equipment and on-site property, do

not operate or service this instrument before reading and understanding this

instruction manual and receiving appropriate training. Save these instructions.

BINOS

®

100 series gas analyzers are intended to be used as analyzers for industrial

purposes. They must not be used in medical, diagnostic or life support applications,

and no independent agency certifications or approvals are to be implied as covering

such applications!

INTENDED USE STATEMENT

Emerson Process Management Manufacturing GmbH & Co. OHG S-V

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

SAFETY INSTRUCTIONS

BINOS

®

100 F and CAT 100 -- HEAVY INSTRUMENTS !

The analyzer variations BINOS

®

100 F and CAT 100 intended to be wall

mounted and/or outdoor installed weigh up to 30 kg resp. 70 kg, depending

on included options!

Use two person and/or suitable tools for transportation and lifting these

instruments!

Take care to use anchors and bolts specified to be used for the weight of

the units!

Take care the wall or stand the unit is intended to be installed at is solid and

stable to hold the units!

HIGH TEMPERATURES !

While working at photometers and/or thermostated components inside the

analyzers hot components may be accessible!

EXPLOSION HAZARD !

Do not operate nor install these instruments in hazardous areas without

additional measures!

Emerson Process Management Manufacturing GmbH & Co. OHGS-VI

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

SAFETY INSTRUCTIONS

Take care of the safety instructions applicable for the gases (sample

gases and test gases) and for the gas bottles containing these gases!

GASES AND GAS CONDITIONING

Before opening gas paths they must be purged with ambient air or

neutral gas (N2) to avoid hazards caused by toxic, flammable,

explosive or harmful to health sample gas components!

Supplying explosive gases is not permitted !

EXPLOSION HAZARD !

Supplying flammable gases of concentrations above 25 % of lower

explosion limit (LEL) we recommend to utilize one or more of the following

measures:

• Purging the housing with inert gas

• Internal tubing with stainless steel

• Flame arrestors at gas input and output fittings

• Intrinsically safe paramagnetical or thermal conductivity sensors

Emerson Process Management Manufacturing GmbH & Co. OHG S-VII

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

SAFETY INSTRUCTIONS

POWER SUPPLY

The mains socket has to be nearby the power supply unit and easily

accessible! Disconnecting from mains requires unplugging the power plug!

To comply with the CE mark requirements use only power supply units of

type VSE 2000, UPS 01 T, DP 157, SL5, SL10 (DP 157 and SL for rack

installation only) or equivalent units. Equivalent units must provide SELV

output voltages!

Verify proper polarity when connecting DC 24 V operated analyzers !

These instruments provide a protective earth terminal. To prevent electrical

shock hazards the instrument must be connected to a protective earth.

Therefore the instrument has to be connected to mains by using a three

wire mains cable with earth conductor!

Any interruption of the earth connector inside or outside the instrument or

disconnecting the earth terminal may cause potential electrical shock

hazzard! Intended interruption of protective earth connections is not

permitted!

ELECTRICAL SHOCK HAZARD !

Verify the mains voltage at site of installation corresponds to the analyzer´s

rated voltage as given on the nameplate label!

Verify the safety instruction given by power supply unit manufacturer !

Instruments with External Power Supply Unit

Instruments with Internal Power Supply Unit

Emerson Process Management Manufacturing GmbH & Co. OHGS-VIII

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Installation and connecting mains and signal cables are subject to qualified

personnel only taking into account all applicable standards and legislative

requirements!

Failure to follow may cause warranty invalidation, property damage and/or

personal injury or death! Mains and signal cables need to be connected to

internal srew terminals requiring to work at open housing near life parts!

Installation of this instrument is subject to qualified personnel only, familiar

with the resulting potential risks!

These gas analyzer do not provide a mains power switch and are operable

when connected to power.

These gas analyzers do not provide a mains switch! A mains switch or circuit

breaker has to be provided in the building installation. This switch has to be

installed near by analyzer, must be easily operator accessible and has to be

assigned as disconnector for the analyzer.

ADDITIONAL HINTS FOR MODELS BINOS

®

100 F AND CAT 100

Cables for external data processing must be double insulated for mains

voltage when used inside the instrument!

If double insulation is not available signal cables inside the analyzer must

be installed in a way that a distance of at least 5 mm is ensured permanently

(e.g. by utilizing cable ties).

ADDITIONAL HINTS FOR MODEL BINOS

®

100 F

SAFETY INSTRUCTIONS

Emerson Process Management Manufacturing GmbH & Co. OHG S-IX

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

Supplying external components utilizing the DC 24 V power output provided

by the BINOS

®

100 2M internal power supply unit requires a fuse to be

connected in series to the load limiting the power to 2 A max!

Verify proper DC 24 V polarity when connecting any external load!

SAFETY INSTRUCTIONS

ADDITIONAL HINTS FOR MODEL BINOS

®

100 2M

Emerson Process Management Manufacturing GmbH & Co. OHGS-X

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

General Operating Instructions

• Installation area has to be clean, free from moisture, excessive vibration and frost-protected.

Take care to meet the permissible ambient temperatures as given in the technical data section!

Instruments must not be exposed to direct sunlight, fluorescent lamps nor sources of heat.For

outdoor installation it is recommended to mount the instruments into a cabinet. At least sheltering

against rain is required. Do not cover venting openings and take care to mount the instrument in

a distance to walls not affecting venting.

• Do not interchange gas inlet and outlet! All gases must be conditioned before supplying! When

supplying corrosive gases ensure that gas path components are not affected!

• Max. permissible gas pressure: 1,500 hPa, except with integrated valve blocks (see hint at

page 3-4) and/or paramagnetic Oxygen sensor (see page 2-15)!

• Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected

and in compliance with applicable legislative requirements!

• When it is necessary to open gas paths seal the analyzer‘s gas fittings by using PVC caps to

avoid pollution of the internal gas path by moisture, dust, etc.

• To stay in compliance with regulations regarding electromagnetic compatibility it is recommended

to use only shielded cables, as optionally available from Emerson Process Management or

equivalent. Customer has to take care that the shield is connected in proper way (see section

3-5). Shield and signal connector enclosure need to be conductively connected, submin-d plugs

and sockets must be screwed to the analyzer.

• Using external submin-d-to-terminal adaptor elements (option) affects electromagnetic

compatibility. In this case the customer has to take measures to stay in compliance and has to

declare conformity, when required by legislation (e.g. European EMC Directive).

General operating instructions

DANGER TO LIFE ! EXPLOSION HAZARD !

Verify all gas lines are connected as described within this manual and tight!

Improper gas connections may cause explosion, serious injury or death!

Exhaust may contain hydrocarbons and other toxic gases, e.g. carbon

monoxide. Carbon monoxide is toxic!

Emerson Process Management Manufacturing GmbH & Co. OHG S-XI

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

Magnetically Operated Front Panel

DANGER TO LIFE !

Persons with cardiac pacemakers should absolutely avoid magnetic

fields !

Negative effects on persons beyond those described above caused by

magnetic fields are not known. It is presumed that persons showing allergic

reaction on contact with ceramic or metallic material show the same

behavior on contact with magnetic material.

Permanent magnets are surrounded by magnetic fields. These magnetic

fields can disturb and even destroy sensitive electronic measuring devices,

but also mechanical watches, credit cards, etc.

Usually a distance of 0.5 m is enough to avoid damages. All sintered

permanent magnets are hard and brittle. Hitting of sintered permanent

magnets by the magnetic attraction causes splitting into fragments with many

sharp edges. This especially occurs with high energy magnets, and can

also cause skin bruises by high attraction.

High energy magnets made of rare-earth materials have to be stored dry,

otherwise the surfaces would oxidise. Unprotected operation in a humid

environment may cause corrosion. Avoid damaging the protective galvanic

coating.

A storage in a hydrogen atmosphere destroys these magnets. A

demagnetisation is caused when permanent magnet materials have been

exposed in a radioactive radiation for a long time.

For air transportation of magnetic material the IATA instructions have to be

observed:

Magnetic fields are not allowed to penetrate the package, if necessary the

magnets have to be shorted using a metal plate.

Emerson Process Management Manufacturing GmbH & Co. OHGS-XII

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Emerson Process Management Manufacturing GmbH & Co. OHG TOC-1

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

Table of Contents

PREAMBLE ................................................................................................................... I

DEFINITIONS ................................................................................................................... I

SAFETY INSTRUCTIONS ..................................................................................................II

CHAPTER 1 TECHNICAL DESCRIPTION................................................................... 1-1

1-1 General Description................................................................................................................ 1-1

1-2 BINOS

®

100, BINOS

®

100 M, OXYNOS

®

100, HYDROS

®

100.............................................. 1-5

1-3 BINOS

®

100 2M ...................................................................................................................... 1-9

1-4 BINOS

®

100 F....................................................................................................................... 1-15

1-5 CAT 100 ................................................................................................................................ 1-22

1-6 Internal Gas Paths ................................................................................................................ 1-30

1-6-1 Gas Paths Materials........................................................................................................... 1-30

1-6-2 Safety Filter......................................................................................................................... 1-30

1-6-3 Fittings.................................................................................................................................1-30

1-6-4 Piping .................................................................................................................................. 1-30

1-6-5 Gas Path Variations............................................................................................................ 1-31

1-7 Technical Data ...................................................................................................................... 1-34

1-7-1 Common Technical Data.................................................................................................... 1-34

1-7-2 Model Specific Data............................................................................................................1-36

1-7-2-1 BINOS

®

100, BINOS

®

100 M, OXYNOS

®

100, HYDROS

®

100 ....................................... 1-36

1-7-2-2 BINOS

®

100 2M................................................................................................................ 1-41

1-7-2-3 BINOS

®

100 F ..................................................................................................................1-48

1-7-2-4 CAT 100 ........................................................................................................................... 1-55

1-7-2-5 External Power Supply Unit for Tabletop and Rack Mount Analyzers.............................. 1-63

1-7-2-6 5 A Power Supply Unit for DIN Rail Installation ...............................................................1-65

1-7-2-7 External 10A Power Supply Unit for DIN Rail Installation ................................................. 1-67

1-7-2-8 10 A Tabletop Power Supply Unit ....................................................................................1-69

1-7-3 Specifications at the Nameplate Label ............................................................................... 1-70

CHAPTER 2 MEASURING PRINCIPLES..................................................................... 2-1

2-1 Infrared Measurement (IR)......................................................................................................2-1

2-1-1 Interference Filter Correlation (IFC)......................................................................................2-1

2-1-2 Opto Pneumatic Measuring Principle...................................................................................2-3

2-1-3 Technical Implementation..................................................................................................... 2-4

2-2 Oxygen Measurement ............................................................................................................ 2-9

2-2-1 Paramagnetic Measurement................................................................................................ 2-9

2-2-2 Electrochemical Measurement .......................................................................................... 2-11

2-2-3 Special Hints on Oxygen Sensors ..................................................................................... 2-13

2-3 Thermal Conductivity Measurement..................................................................................... 2-14

2-3-1 Principle of Operation ......................................................................................................... 2-14

2-3-2 Technical Implementation................................................................................................... 2-15

2-4 Measurement Specification .................................................................................................. 2-16

Emerson Process Management Manufacturing GmbH & Co. OHGTOC-2

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Table of Contents

CHAPTER 3 INSTALLATION ....................................................................................... 3-1

3-1 Abstract................................................................................................................................... 3-1

3-2 Gas Conditioning .................................................................................................................... 3-2

3-3 Gas Connections.................................................................................................................... 3-3

3-4 Analyzer Specific Instructions.................................................................................................3-5

3-4-1 1/4 19" Instruments...............................................................................................................3-5

3-4-2 1/2 19" Instruments...............................................................................................................3-9

3-4-3 BINOS

®

100 F.....................................................................................................................3-14

3-4-4 CAT 100 .............................................................................................................................. 3-21

3-5 Wiring Signal Terminals........................................................................................................ 3-27

3-5-1 Electrical Connections in General ...................................................................................... 3-27

3-5-2 Wiring Inductive Loads ....................................................................................................... 3-29

3-5-3 Driving Multiple Loads ........................................................................................................ 3-29

3-5-4 Driving High Current Loads ................................................................................................ 3-30

CHAPTER 4 OPERATION ........................................................................................... 4-1

4-1 Abstract................................................................................................................................... 4-1

4-2 Button "FUNCTION"................................................................................................................ 4-4

4-3 Button "ENTER"...................................................................................................................... 4-6

4-4 Buttons "INPUT - CONTROL" ................................................................................................ 4-6

4-5 Button "PUMP" ........................................................................................................................ 4-7

4-6 Software Menu Structure ........................................................................................................ 4-7

4-7 Magnetically Operated Front Panel ........................................................................................ 4-9

4-7-1 Front Panel Elements ........................................................................................................... 4-9

4-7-2 Accessory............................................................................................................................. 4-9

4-7-3 Operating the Front Panel...................................................................................................4-10

4-7-4 Storing the Actuator Tool..................................................................................................... 4-11

CHAPTER 5 STARTUP ............................................................................................... 5-1

5-1 Abstract................................................................................................................................... 5-1

5-2 Software Menu Structure ........................................................................................................ 5-2

5-3 Checking System Parameter Settings................................................................................... 5-3

5-3-1 Menu "System Parameter"..................................................................................................5-3

5-3-2 Menu "Druckkorrektur"........................................................................................................5-4

5-3-3 Menu "Internal Cross Compensation´"................................................................................5-4

5-3-4 Menu "Calibrate Cross Compensation" ..............................................................................5-5

5-3-5 Menu "Hold" ......................................................................................................................... 5-6

5-3-6 Menu "Automatic Calibration".............................................................................................. 5-6

5-3-7 Menu "Tolerance Check"..................................................................................................... 5-7

5-3-8 Menu "Display Off" .............................................................................................................. 5-8

5-3-9 Menu "Gas Path Purge Time" ............................................................................................. 5-9

5-3-10 Menu "Access Code" ..........................................................................................................5-9

Emerson Process Management Manufacturing GmbH & Co. OHG TOC-3

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BINOS

®

100 Series

Table of Contents

5-3-11 Menus "Response Time t90"...........................................................................................5-10

5-3-12 Menu "Reset"..................................................................................................................... 5-11

5-3-13 Menu "Software Revision" ................................................................................................. 5-12

5-3-14 Menus "Analyzer Serial Number"...................................................................................... 5-12

5-3-15 Menu "Pump Status" *)......................................................................................................5-13

5-3-16 Menu "Pump Control" *) ....................................................................................................5-13

5-4 Analog Outputs ....................................................................................................................5-14

5-4-1 Menu "Life-Zero for Analog Outputs"................................................................................. 5-15

5-4-2 Menu "Adjusting Analog Outputs"......................................................................................5-16

5-4-3 Menu "Analog Output Offset" ............................................................................................5-18

5-4-4 Menu "Analog Output Upper Limit"....................................................................................5-19

5-5 Digital Outputs ...................................................................................................................... 5-20

5-5-1 Concentration Threshold Operation Modes ....................................................................... 5-20

5-5-2 Setting Concentration Thresholds ...................................................................................... 5-24

5-5-3 Valve Control.......................................................................................................................5-26

5-5-4 Wiring Digital Outputs......................................................................................................... 5-26

5-6 Calibration Procedures......................................................................................................... 5-27

5-6-1 Manual Calibration .............................................................................................................. 5-28

5-6-1-1 Zero Calibration ................................................................................................................ 5-28

5-6-1-2 Span Calibration ............................................................................................................... 5-30

5-6-2 Time Controlled Calibration ................................................................................................ 5-32

5-6-2-1 Zero Calibration ................................................................................................................ 5-32

5-6-2-2 Combined Zero and Span Calibration.............................................................................. 5-34

5-7 Remote Calibration (Option)................................................................................................. 5-35

5-8 Measuring ............................................................................................................................ 5-36

5-9 Taking Out of Operation ........................................................................................................ 5-37

CHAPTER 6 DESCRIPTION OF OPTIONS ................................................................. 6-1

6-1 Relay Status Signals............................................................................................................... 6-2

6-2 Serial Interface........................................................................................................................ 6-3

6-2-1 Enabling / Disabling Serial Interface..................................................................................... 6-5

6-2-2 Configuring the Interface.......................................................................................................6-5

6-2-3 Communication..................................................................................................................... 6-7

6-2-3-1 Telegram Syntax ................................................................................................................6-8

6-2-3-2 Status Telegram .................................................................................................................6-9

6-2-3-3 Number Formats.............................................................................................................. 6-10

6-2-3-4 Longitudinal Parity Test .................................................................................................... 6-10

6-2-3-5 Command Syntax ............................................................................................................ 6-10

6-2-3-6 List of Available Commands ............................................................................................ 6-11

6-2-3-7 Reply Telegrams .............................................................................................................. 6-12

6-2-3-7-1 Status Messages (Command 030) ................................................................................ 6-12

6-2-5-7-2 Pump Status (Command 008) *).................................................................................... 6-13

Emerson Process Management Manufacturing GmbH & Co. OHGTOC-4

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Table of Contents

6-3 Option Digital Inputs / Foundation™ Fieldbus ...................................................................... 6-14

6-3-1 Digital Inputs ....................................................................................................................... 6-14

6-3-2 Starting a Calibration Procedure......................................................................................... 6-15

6-3-3 Valve Control....................................................................................................................... 6-15

6-3-4 Pump Control...................................................................................................................... 6-15

6-3-5 Foundation™ Fieldbus....................................................................................................... 6-16

6-4 Cross Compensation (TCD) ................................................................................................ 6-17

6-5 Fine Dust Filter / Needle Valve ........................................................................................... 6-18

6-5-1 Fine Dust Filter.................................................................................................................... 6-18

6-5-2 Needle Valve....................................................................................................................... 6-18

6-6 Flowmeter............................................................................................................................. 6-19

CHAPTER 7 BUG FIXING ........................................................................................... 7-1

7-1 Error Codes ............................................................................................................................7-1

7-2 Other Problems ...................................................................................................................... 7-6

CHAPTER 8 TROUBLESHOOTING ON ELECTRONICS............................................ 8-1

8-1 Getting Access to Internal Analyzer Components .................................................................. 8-2

8-1-1 BINOS

®

100 (M), OXYNOS

®

100, HYDROS

®

100 ............................................................. 8-2

8-1-2 BINOS

®

100 2M.................................................................................................................... 8-8

8-1-3 BINOS

®

100 F..................................................................................................................... 8-14

8-1-4 CAT 100 .............................................................................................................................. 8-16

8-2 Measuring Points .................................................................................................................. 8-23

8-2-1 Measuring Points at BKS ...................................................................................................8-23

8-2-1-1 Supply voltage +6 V ......................................................................................................... 8-23

8-2-1-2 Positive reference voltage................................................................................................ 8-23

8-2-1-4 Temperature sensor......................................................................................................... 8-25

8-2-1-3 Negative reference voltage .............................................................................................. 8-25

8-2-1-5 Light barrier signal............................................................................................................ 8-25

8-2-1-6 Analog Preamplifier .......................................................................................................... 8-26

8-2-2 Measuring Points at OXS (Electrochemical Oxygen Measurement) ............................... 8-27

8-2-2-1 Sensor Signal................................................................................................................... 8-27

8-3 Position and Assignment of Connectors on Electronics Boards .......................................8-28

8-3-1 BKS..................................................................................................................................... 8-28

8-3-1-1 IR Measurement w/o Oxygen Sensor.............................................................................. 8-29

8-3-1-2 Oxygen Measurement w/o IR .......................................................................................... 8-29

8-3-1-3 Combination of IR and Oxygen Measurement................................................................ 8-29

8-3-1-4 TCD w/o IR channel......................................................................................................... 8-29

8-3-1-5 Combined IR and TCD Measurement ............................................................................8-30

8-3-1-6 Combined Oxygen and TCD Measurement .................................................................... 8-30

8-3-2 OXS (Electrochemical Oxygen Measurement)................................................................. 8-31

8-3-3 WAP 100 (TC Measurement)............................................................................................. 8-32

Emerson Process Management Manufacturing GmbH & Co. OHG TOC-5

Instruction Manual

HAS1xE-IM-HS

03/2005

BINOS

®

100 Series

8-4 BKS 20 Jumper Configuration.............................................................................................. 8-33

CHAPTER 9 MAINTENANCE ...................................................................................... 9-1

9-1 Replacing the Fine Dust Filter ................................................................................................9-2

9-2 Leak Testing............................................................................................................................ 9-3

9-3 Cleaning the Analyzer´s Outside ............................................................................................ 9-4

9-4 Replacing the Electrochemical Oxygen Sensor .................................................................... 9-5

9-4-1 Analyzer with Oxygen Measurement only, no IR Channel................................................... 9-6

9-4-2 Analyzer with Combined IR and Oxygen measurement...................................................... 9-7

9-4-3 Replacing the Sensor ........................................................................................................... 9-7

9-4-4 Reassembling the Sensor Unit............................................................................................. 9-8

9-4-5 Sensor Amplifier Adjustment ................................................................................................9-8

9-5 Magnetically Operated Front Panel ........................................................................................ 9-9

APPENDIX A-1

A-1 Block Diagrams ......................................................................................................................A-2

A-1-1 BINOS

®

100 (M), OXYNOS

®

100, HYDROS

®

100 ............................................................ A-2

A-1-2 BINOS

®

100 2M................................................................................................................... A-3

A-1-3 BINOS

®

100 F...................................................................................................................... A-4

A-1-4 CAT 100 ............................................................................................................................... A-5

A-2 Declarations of Conformity .....................................................................................................A-9

A-2-1 BINOS

®

100 (M), OXYNOS

®

100, HYDROS

®

100 ............................................................ A-9

A-2-2 BINOS

®

100 2M................................................................................................................. A-10

A-2-3 BINOS

®

100 F.....................................................................................................................A-11

A-2-4 CAT 100 ............................................................................................................................. A-12

Table of Contents

Emerson Process Management Manufacturing GmbH & Co. OHGTOC-6

BINOS

®

100 Series

Instruction Manual

HAS1xE-IM-HS

03/2005

Fig. 4-1: BINOS

®

100 (M), OXYNOS

®

100, HYDROS

Fig. 4-2: BINOS

®

100 2M (standard version) front sid

Fig. 4-3: Magnetically operated front panel ...............

Table of Illustrations

CHAPTER 1 TECHNICAL DESCRIPTION

Fig. 1-1: BINOS

®

100 (M), OXYNOS

®

100, HYDROS

®

100, front side view ...................................... 1-6

Fig. 1-2: BINOS

®

100 (M), OXYNOS

®

100 (EO2), HYDROS

®

100, rear side view............................ 1-7

Fig. 1-3: OXYNOS

®

100 (PO2), rear side view................................................................................... 1-8

Fig. 1-4: BINOS

®

100 2M (standard version) front side view............................................................ 1-11

Fig. 1-5: BINOS

®

100 2M, variation A (internal power supply) Rear side view with all options........ 1-12

Fig. 1-6: BINOS

®

100 2M, variation B (external power supply) Rear side view with all options ...... 1-13

Fig. 1-7: BINOS

®

100 2M (special variation), Rear side view with all options .................................1-14

Fig. 1-8: BINOS

®

100 F Standard version, front side view................................................................ 1-18

Fig. 1-9: BINOS

®

100 F Standard front panel incl. sample handling options.................................... 1-19

Fig. 1-10: BINOS

®

100 FMagnetically operated front panel (option)................................................... 1-20

Fig. 1-11: BINOS

®

100 F Interior view (without components)............................................................ 1-21

Fig. 1-12: CAT 100 Exterior view......................................................................................................... 1-25

Fig. 1-13: CAT 100 (Dome and extender housing removed).............................................................. 1-26

Fig. 1-14: CAT 100 Front panel ........................................................................................................... 1-27

Fig. 1-15: CAT 100 Junction box, interior view................................................................................... 1-28

Fig. 1-16: CAT 100 Gas fittings and assignment ................................................................................ 1-29

Fig. 1-17: Single channel or serial tubing............................................................................................ 1-31

Fig. 1-18: Dual channel parallel tubing................................................................................................ 1-31

Fig. 1-19: Single channel resp. serial tubing, with options.................................................................. 1-32

Fig. 1-20: Parallel tubing, with options ................................................................................................ 1-33

Fig. 1-21: BINOS

®

100 (M) / OXYNOS

®

100 / HYDROS

®

100 dimensions........................................ 1-36

Fig. 1-22: Pin assignment 24 V DC input plug.................................................................................... 1-37

Fig. 1-23: Socket X2 pin assignment (analog signal outputs; standard) ............................................1-37

Fig. 1-26: Plug Analog IN pin assignment (cross compensation; option).......................................... 1-38

Fig. 1-25: Plug X3 pin assignment (digital outputs; standard) ............................................................ 1-38

Fig. 1-24: Connecting digital outputs................................................................................................... 1-38

Fig. 1-27: Socket X4 pin assignment (serial interface; option) ......................................................... 1-39

Fig. 1-28: Relay status signals, block diagram................................................................................... 1-40

Fig. 1-29: Plug X1 pin assignment (relay status signals; option)........................................................ 1-40

Fig. 1-30: BINOS

®

100 2M dimensions............................................................................................... 1-41

Fig. 1-31a: Pin assignment 24 V DC input plug.................................................................................... 1-42

Fig. 1-31b: Pin assignment 24 V DC output socket.............................................................................. 1-42

Fig. 1-31c: IEC mains input plug........................................................................................................... 1-42

Fig. 1-32: Socket X2 pin assignment (analog signal outputs; standard) ............................................1-43

Fig. 1-34: Plug Analog IN pin assignment (cross compensation; option).......................................... 1-44

Fig. 1-34: Plug X3 pin assignment (digital outputs; standard) ............................................................ 1-44

Fig. 1-33: Connecting digital outputs................................................................................................... 1-44

Fig. 1-36: Socket X4 pin assignment (serial interface; option) ......................................................... 1-45

Fig. 1-38: Plug X1 pin assignment (relay status signals; option)........................................................ 1-46

Fig. 1-37: Relay status signals, block diagram................................................................................... 1-46

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Rosemount BINOS 100 Series Analyzers including OXYNOS 100, HYDROS 100 and CAT 100-2nd Ed. Owner's manual

Rosemount BINOS 100 Series Analyzers including OXYNOS 100, HYDROS 100 and CAT 100-2nd Ed. Owner's manual

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